Modular cupola assembly

ABSTRACT

The present invention relates to kit for a cupola assembly. The cupola assembly utilizes injection molded plastic panels having integrally formed connectors. The cupola is capable of being packaged and shipped in a knocked-down state and constructed into a secure cupola.

FIELD OF THE INVENTION

This invention relates generally to a cupola device constructed ofplastic structural panels. More specifically, the present inventionrelates to a cupola kit utilizing modular injection molded plasticpanels. The cupola kit is capable of being packaged and shipped in aknocked-down state and constructed into a secure cupola assembly upon adesired site.

BACKGROUND INFORMATION

Permanent structures such as utility sheds or garages are often utilizedfor storage of household items such as gardening tools, children's toys,barbeque accessories and the like. A common addition to the roof of suchstructures is the cupola. Cupolas have been part of architectural designfor many years. Most cupolas are constructed of wood, with metal orshingle roofs, and may include windows to admit light or louvers to venthot air out of the structure to which they are attached.

Wooden cupolas are generally custom made for a particular roof and thusassembly and installation require a great deal of time and expertise.Because these structures are made of wood they also require a great dealof maintenance to prevent degradation during the life of the structureto which they are attached.

Metal cupolas are also known in the art. Metal cupolas generally includea plurality of metal panels having turned up edges that are assembled byaligning the turned up edges and thereafter sliding a U-shaped retainerover the joint to hold the panels in position. For example, Nystrom U.S.Pat. No. D413,170 discloses an ornamental design for a metal cupola.Post Jr. Discloses a pre-fabricated cupola and mounting bracket. Forsmanet al. Discloses a cupola having and adjustable mount.

Also known in the art of metal cupolas are panels with snap-fit edges.For example, Coolman U.S. Pat. No. 6,170,206 discloses a cupola roofhaving panels with snap-fit edges. Each combination cupola roof panelhas a female snap-fit edge on one side and a female snap-fit edge on theother side.

It is also known to combine metal panels and plastic panels into acupola structure. For example, Wilhelmson discloses a satellite dishhousing and roof ventilation device. The device includes panelsconstructed of radio-frequency transparent material so that televisionreception is not impaired.

Another cupola construction known in the art utilizes a roto-moldedconstruction wherein all four sides of the cupola are formed as a singlepiece. See Van Gilst et al. U.S. Pat. No. 6,422,936.

Such prior art systems, while working well, have not met all of theneeds of manufacturers to provide a product that can be easilymanufactured, packaged and shipped or the needs of consumers requiringstructural integrity combined with modularity and aesthetic appearance.

For example, the metal structures of the prior art include numeroussharp edges and are difficult to assemble. In addition, the thin sheetmetal panels are easily bend during shipping and assembly. Thecombination plastic and metal structures do not include any integratedfasteners and thus require substantial skill as well as numerous toolsto assemble. The roto-molded structures do not break down into smallcomponents and thus are expensive and difficult to ship.

In addition, due to the nature of the manufacturing processes utilizedfor constructing the prior art cupolas, the panel components cannot beformed with the intricate shapes and/or cross sections required forintegrated connectors. Therefore, these systems require a substantialnumber of fasteners in combination with connector members having aspecific cross-sectional geometry that facilitate an engagement betweenthe panels to complete the structure.

Therefore, what is needed in the art is an injection molded modularcupola assembly. The modular cupola assembly should achieve objectivessuch as lightweight single walled panel construction. The constructionof the panels should eliminate the need for additional connectors tocreate a cupola assembly which resists panel separation, buckling, andracking. The cupola assembly should be capable of withstanding the snowand wind loads typically associated with enclosures. Also, from aconvenience standpoint, the cupola assembly should include featuresconstructed to cooperate with lighting and/or fans or otherenhancements. In addition, the cupola assembly should includeconvenience features that allow the cupola to be easily attached to anenclosure.

There are also commercial considerations that must be satisfied by anyviable cupola assembly or kit; considerations which are not entirelysatisfied by state of the art products. The cupola assembly must beformed of relatively few component parts that are inexpensive tomanufacture by conventional techniques, such as injection molding. Thecupola assembly must also be capable of being packaged and shipped in aknocked-down state. In addition, the cupola assembly must be modular andfacilitate the creation of a family of cupola assemblies for enclosuresthat vary in size but which share common, interchangeable components.

Finally, there are ergonomic needs that a cupola assembly must satisfyin order to achieve acceptance by the end user. The cupola assembly mustbe easily and quickly assembled using minimal hardware and requiring aminimal number of tools. Further, the cupola assembly must not requireexcessive strength to assemble or include heavy component parts.Moreover, the cupola assembly must assemble together in such a way so asnot to detract from the appearance or function of the resultingenclosure, or otherwise negatively affect the utility of the structure.

The assignee of the instant invention is also the assignee of variousother plastic enclosure systems, U.S. Pat. No. 6,892,497 entitledPlastic Panel Enclosure System, U.S. patent application Ser. No.10/729,689 filed Dec. 5, 2003, entitled Low Profile Plastic PanelEnclosure, and U.S. patent application Ser. No. 10/674,103 filed Aug.29, 2003, entitled Plastic Expandable Utility Shed, the contents ofwhich are incorporated herein in their entirety.

BRIEF DESCRIPTION OF THE INVENTION

The present invention provides a system, or kit, of injection moldedpanels having integrated connectors which combine to form a roofmountable cupola. The panels are formed of injection molded plastic tointerlock with one another without the need for separate fasteners orconnectors. The system incorporates a minimum number of components toconstruct a cupola by integrally forming the connectors into theinjection molded panels. This minimizes the need for separate extrudedor molded connectors to assemble the cupola. The integrated connectionof the side walls and cover components also simplifies cupolaconstruction. Injection molding allows the panels to be formed withintegral cross-bracing, ribs and gussets for increased rigidity whencompared to blow molded or extruded panels. The same side wall and coverpanel components may be used to create a variety of cupolas and theassembly thereof requires minimal hardware and a minimum number of handtools.

The front and rear wall panels have outwardly projecting locking postsfor interlocking cooperative engagement with sockets in the left andright side wall panels. The engagement between the locking posts and thesockets serve to rigidly connect the components together. The systemfurther includes a cover which slides into place after the front, rear,left and right wall panels have been fully assembled. The cover mayinclude spring locks for engagement with the side panels oralternatively may be held in place with suitable fasteners. The systemis constructed to allow various cover panels to be utilized furtherincreasing the utility of the assembled cupola.

Accordingly, it is an objective of the present invention to provide amodular cupola assembly having integrated connectors for creatingvarious cupolas using common components.

A further objective is to provide a modular cupola assembly wherein thepanels include integrated connectors accommodated by injection moldingplastic formation for increased structural integrity.

Yet a further objective is to provide a modular cupola assembly in whichthe side walls and cover panels are integrally interlocked withoutseparate connectors or fasteners.

Another objective is to provide an cupola assembly constructed ofmodular panels having a cover panel which allows interchangeabilityafter all other parts are assembled.

Yet another objective is to provide a kit for a cupola that is capableof being packaged and shipped in a knocked-down state and constructedinto a secure cupola upon a desired site.

Other objectives and advantages of this invention will become apparentfrom the following description taken in conjunction with theaccompanying drawings wherein are set forth, by way of illustration andexample, certain embodiments of this invention. The drawings constitutea part of this specification and include exemplary embodiments of thepresent invention and illustrate various objects and features thereof.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of one embodiment of the cupola assembly;

FIG. 2 is a perspective view of the inner surface of a wall panelutilized in the instant invention;

FIG. 3 is a perspective view of the front and rear panels of embodimentshown in FIG. 1;

FIG. 4 is a perspective exploded view of the wall panels utilized in theinstant invention;

FIG. 5 is a bottom view of one embodiment of the top panel utilized inthe instant invention;

FIG. 6 is a perspective view illustrating assembly of the top panel;

FIG. 7 is front plan view of the instant invention;

FIG. 8 is a section view taken along line 1-1 of the cupola embodimentshown in FIG. 7 illustrating the cooperative engagement between the sidepanels and cover panel;

FIG. 9 is a side plan view of the instant invention;

FIG. 10 is a section view taken along line 2-2 of the cupola embodimentshown in FIG. 9 illustrating the cooperative engagement between the sidepanels and cover panel;

FIG. 11 is a perspective view illustrating the instant invention in ashipping configuration.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

While the present invention is susceptible of embodiment in variousforms, there is shown in the drawings and will hereinafter be describeda presently preferred embodiment with the understanding that the presentdisclosure is to be considered an exemplification of the invention andis not intended to limit the invention to the specific embodimentsillustrated.

FIGS. 1-10 which are now referenced illustrate perspective, exploded andsectioned views of the cupola assembly and kit therefor, generallyreferenced as 100, according to a preferred embodiment of the presentinvention. The cupola assembly is made up of substantiallylike-constructed left wall panel and right side panel 200, substantiallylike constructed rear side panel and front side panel 300 and coverpanel 400. In the preferred embodiment, the panels comprising theassembly are formed of but not limited to a suitable plastic such aspolystyrene, polypropylene, polyvinyl chloride, polyethylene or thelike, through the process of injection molding. The result is that theside and cover panels comprising the cupola assembly 100 are formed asunitary panels with integral connectors, and cross bracing.Strengthening ribs 202 and gussets 204 are formed within the innersurfaces of the side panels 200, 300 and cover panel 400 in order toenhance rigidity of the panels while leaving the external surface in agenerally smooth condition for aesthetic purposes, as shown in FIG. 1.

Referring to FIG. 2, the inner surface 302 of the front and rear sidepanels 300 is shown. The front and rear side panels 300 are eachconfigured having a first end 308 and a second end 312. Both ends 308,312 include an integrally formed first attachment means illustrated asat least one outwardly extending attachment post 310. The attachmentposts 310 are generally constructed and arranged to cooperate withinwardly extending sockets 208 provided in either end of the left andright panels 200. The top surface 314 includes a second attachment meansillustrated herein as one side of an upwardly extending boss 316. Whenall four side panels are assembled the boss 316 is constructed andarranged to cooperate with a socket 408 (FIG. 5) that extends around theperimeter of the lower surface of the cover panel 400.

Referring to FIG. 4, the left and right side panels 200 are shown. Theleft and right side panels include a top surface 205, bottom surface206, first end 210 and second end 212. Adjacent to each of the first andsecond edges 210, 212 is a means of attaching the left and right sidepanels 200 to the front and rear side panels 300 illustrated herein as aplurality of integrally formed sockets 216 extending downwardly fromabout the top surface 205 to about the bottom surface 206. The formedsockets 216 are constructed and arranged to cooperate with locking posts310 extending outwardly along the first and second edges 308, 312 of thefront and rear side panels 300. The locking posts 310 and sockets 216are constructed and arranged so that the locking posts 310 enter andmateably engage the sockets 216 securing the panels together in aninter-fitting engagement with their respective outer surfaces in aperpendicular arrangement.

Referring to FIG. 5, the bottom surface of the cover panel 400 isillustrated. The bottom surface of the cover panel 400 is constructedwith a socket 408 extending around the perimeter of the bottom surface402. The socket 408 is constructed and arranged to cooperate with theboss 316 (FIG. 4) extending upwardly from the top surfaces of the front,back, and side panels. The boss 316 and socket 408 arrangement increasesthe structural integrity of the cupola assembly 100 by preventing thepanels 200, 300 from bowing or bending inwardly or outwardly, and thus,adversely affecting the appearance or operation of the cupola 100.

Referring to FIGS. 1-10, the outer surface of the side panels 200, 300are constructed generally smooth having a plurality of inwardly bowedgrooves 218 for added strength and aesthetic appearance. In analternative embodiment, a portion of each groove includes an elongatedaperture (not shown). In this embodiment, the apertures are constructedand arranged to allow air to flow through the cupola for ventilation ofthe structure to which it is attached as is well known in the art. Theinside surface of the side panels 200, 300 are constructed with aplurality of integrally formed strengthening ribs 202 extending acrossthe panels with a portion of the ribs 202 being provided with aplurality of gussets 204 to further strengthen the panels. The ribs 202and gussets 204 increase the structural integrity of the cupola 100 bypreventing the side panels 200, 300 from bowing or bending inwardly oroutwardly, and thus, adversely affecting the appearance or operation ofthe cupola 100. The integrally formed ribs 202 and gussets 204 arefacilitated by injection molding. Injection molding offers significantstrength and stability advantages over cupola constructions utilized inthe prior art. In this manner the cupola assembly of the instantinvention is capable of handling a significant amount of snow and windloads.

Referring to FIG. 4, the left and right side panels 200 are attached tothe front and rear panels 300 by inserting the locking posts 310 intosockets 216 until the spring tabs 318 integrally formed onto the lockingposts 310 engage the apertures 220 integrally formed into the sockets216 of the left and right side panels 200. It will be appreciated thatthe purpose of the locking posts 310 are to align two panels in aperpendicular relationship and to facilitate their mechanicalconnection. The perpendicular panels are brought into an overlappingrelationship wherein the contoured locking posts 310 enter thecorresponding socket 216 in the left and right panels 200. The result isa mechanically secure connection between the two panels. The overlappingedges between the panels as described above provides a secure connectionand offers several advantages. First, the design allows the panels to beconnected without the need for separate connectors. Second, the designcreates a positive lock that prevents separation of the panels. Third,the design maintains alignment of the panels and prevents bowing orbending of either panel relative to one another. The resultant cupolaassembly created by the combination of the interlocking panels benefitsfrom high structural integrity and reliable operation.

Referring to FIG. 6, the side panels 200, 300 are attached to the coverpanel 400 by sliding the boss 316 formed along the top edges 205, 314 ofthe assembled side panels into the corresponding socket 408 integrallyformed into the bottom surface of the cover panel. The socket 408 in thecover panel 400 corresponds in shape and size to that of the boss 316.In one embodiment spring tabs 318 integrally formed onto the boss 316align with apertures 220 in the socket 408 to engage the cover panel tothe side panels 200 and 300. In an alternative embodiment self threadingfasteners (not shown) are inserted through apertures 220 for engagementa side surface 410 of the cover socket. The result of either embodimentis a positive mechanical connection between the side panels 200, 300,and the cover panel 400.

Referring to FIG. 11, the kit for assembling a cupola is illustrated ina knocked-down configuration. Within this compact configuration thecupola may be packaged, shipped and stored more economically than priorart cupolas.

All patents and publications mentioned in this specification areindicative of the levels of those skilled in the art to which theinvention pertains. All patents and publications are herein incorporatedby reference to the same extent as if each individual publication wasspecifically and individually indicated to be incorporated by reference.

It is to be understood that while a certain form of the invention isillustrated, it is not to be limited to the specific form or arrangementherein described and shown. It will be apparent to those skilled in theart that various changes may be made without departing from the scope ofthe invention and the invention is not to be considered limited to whatis shown and described in the specification.

One skilled in the art will readily appreciate that the presentinvention is well adapted to carry out the objectives and obtain theends and advantages mentioned, as well as those inherent therein. Theembodiments, methods, procedures and techniques described herein arepresently representative of the preferred embodiments, are intended tobe exemplary and are not intended as limitations on the scope. Changestherein and other uses will occur to those skilled in the art which areencompassed within the spirit of the invention and are defined by thescope of the appended claims. Although the invention has been describedin connection with specific preferred embodiments, it should beunderstood that the invention as claimed should not be unduly limited tosuch specific embodiments. Indeed, various modifications of thedescribed modes for carrying out the invention which are obvious tothose skilled in the art are intended to be within the scope of thefollowing claims.

1. A kit for a cupola assembly comprising: a left side panel forenclosing the left side of said cupola assembly, said left side panelincluding a first edge and a second edge, said first and said secondedges including an integrally formed first means for connecting toadjacently positioned panel members; a right side panel for enclosingthe right side of said cupola assembly, said right side panel includinga first edge and a second edge, said first and said second edgesincluding an integrally formed first means for connecting to adjacentlypositioned panel members; a rear side panel for enclosing the back ofsaid cupola assembly, said rear side panel including a first edge and asecond edge, said first and said second edges including an integrallyformed first means for connecting to adjacently positioned panelmembers; a front panel for enclosing the front of said cupola assembly,said front side panel including a first edge and a second edge, saidfirst and said second edges including an integrally formed first meansfor connecting to adjacently positioned panel members; a cover panel forenclosing the top of said cupola assembly; wherein said cupola assemblycan be shipped in a disassembled compact configuration and assembled ona desired site.
 2. The kit for a cupola assembly of claim 1 wherein saidleft and said right side panel each include a top surface, each said topsurface having a second means of connecting for securing said coverpanel to said top surface.
 3. The kit for a cupola assembly of claim 2wherein said second means of connecting includes at least one upwardlyextending boss, wherein said at least one boss is constructed andarranged to cooperate with a socket integrally formed into a bottomsurface of said cover panel, wherein said cover panel is secured ininterlocking engagement with said left side panel and said right sidepanel.
 4. The kit for a cupola assembly of claim 1 wherein said leftside panel, said right side panel, said front side panel and said rearside panel each include a top surface, each said top surface having asecond means of connecting for securing said cover panel to said topsurface.
 5. The kit for a cupola assembly of claim 4 wherein said secondmeans of connecting includes at least one upwardly extending boss,wherein a portion of said at least one boss is formed by said left saidpanel, said right side panel, said front side panel and said rear sidepanel, wherein said at least one boss constructed and arranged tocooperate with a socket integrally formed into a bottom surface of saidcover panel, wherein said cover panel is secured in interlockingengagement with said left side panel, said right side panel, said frontside panel and said rear side panel.
 6. The kit for a cupola assembly ofclaim 4 wherein said first means for connecting includes at least oneintegrally formed locking post extending outwardly from each of saidfirst and said second edges of said front side panel and said rear sidepanel, wherein said first and said second edges of said front side paneland said rear side panel each include at least one inwardly extendingsocket, wherein said side panels are positioned substantiallyperpendicular with respect to each other and wherein said at least onelocking post of said front and said rear side panel are constructed andarranged to enter a corresponding socket of an adjacently positionedleft or right side panel resulting in a mechanically secure connectiontherebetween.
 7. The kit for a cupola assembly of claim 6 wherein saidfirst and said second edges of said front and said rear side panelsinclude at least two of said locking posts arranged in a linear fashionalong said first and said second edges, wherein said right side paneland said left side panel include at least two said sockets arranged in alinear fashion along said first and said second edges thereof.
 8. Thekit for a cupola assembly of claim 6 wherein each of said at least onelocking post includes at least one spring lock integrally formedthereto, wherein said at least one spring lock is constructed andarranged to interlock with an adjacently positioned front side panel orrear side panel to provide a secure connection therebetween.
 9. The kitfor a cupola assembly of claim 8 wherein said front and said rear sidepanels include at least one aperture positioned to cooperate with saidat least one spring lock, wherein said at least one spring lock entersand engages said at least one aperture for interlocking engagementbetween two substantially perpendicular side panels.
 10. The kit for acupola assembly of claim 1 wherein left side panel and said right sidepanel are substantially similar in construction.
 11. The kit for acupola assembly of claim 1 wherein left side panel and said right sidepanel are identical in construction.
 12. The kit for a cupola assemblyof claim 1 wherein front side panel and said rear side panel aresubstantially similar in construction.
 13. The kit for a cupola assemblyof claim 1 wherein left side panel and said right side panel areidentical in construction.
 14. The kit for a cupola assembly of claim 1wherein at least one of said left side panel, said right side panel,said front side panel and said rear side panel include a means forventilating a structure to which said cupola is attached.
 15. The kitfor a cupola assembly of claim 14 wherein said means for ventilatingincludes a plurality of apertures extending through said at least onepanel, whereby air is free to flow into and out of said cupola.
 16. Akit for assembling a cupola comprising: a left side panel, a right sidepanel, a front side panel, a rear side panel and a cover panel, whereineach said panel includes connectors integrally formed thereto forassembling said cupola without additional fasteners, wherein said cupolamay be shipped in a disassembled compact state and wherein said cupolamay be snapped together at a desired site.
 17. A cupola assemblycomprising: a left side panel having monolithic construction including;a first end having a first means of connecting for interlockingcooperation with a second end of a front side panel in a substantiallyperpendicular relationship; a second end having said first means ofconnecting for interlocking cooperation with a first end of a rear sidepanel in a substantially perpendicular relationship; a top edge having asecond means of connecting for interlocking cooperation with a coverpanel; a bottom edge having a depending lip constructed and arranged toaccept fasteners for attaching said cupola to a building structure; aninner surface; an outer surface; a right side panel having monolithicconstruction including; a first end having said first means ofconnecting for interlocking cooperation with a second end of said rearside panel in a substantially perpendicular relationship; a second endhaving said first means of connecting for interlocking cooperation witha first end of said front side panel in a substantially perpendicularrelationship; a bottom edge having a depending lip constructed andarranged to accept fasteners for attaching said cupola to a buildingstructure; an inner surface; an outer surface; a front side panel havingmonolithic construction including; a first end having said first meansof connecting for interlocking cooperation with said second end of saidright side panel in a substantially perpendicular relationship; a secondend having said first means of connecting for interlocking cooperationwith said first end of said right side panel in a substantiallyperpendicular relationship; a bottom edge having a depending lipconstructed and arranged to accept fasteners for attaching said cupolato a building structure; an inner surface; an outer surface; a rear sidepanel having monolithic construction including; a first end having saidfirst means of connecting for interlocking cooperation with said secondend of said right side panel in a substantially perpendicularrelationship; a second end having said first means of connecting forinterlocking cooperation with said first end of said right side panel ina substantially perpendicular relationship; a bottom edge having adepending lip constructed and arranged to accept fasteners for attachingsaid cupola to a building structure; an inner surface; an outer surface;wherein said cupola may be shipped in a disassembled compact state andwherein said cupola may be snapped together at a desired site.
 18. Thecupola assembly of claim 17 wherein said inner surface of said left sidepanel, said right side panel, said front side panel and said rear sidepanel each include at least one rib extending at least partially acrosssaid inner surface, wherein said at least one rib increases thestructural integrity of said cupola by inhibiting said panels frombowing or bending inwardly or outwardly.
 19. The cupola assembly ofclaim 17 wherein said inner surface of said left side panel, said rightside panel, said front side panel and said rear side panel each includeat least one gusset extending between said inner surface and said atleast one rib, wherein said at least one gusset increases the structuralintegrity of said cupola by inhibiting said panels from bowing orbending inwardly or outwardly.